DIE SHEET HYDROFORMING OF A COMPLEX-SHAPED AA2024-W AIRCRAFT SKIN PANEL — FROM CONCEPT TO FINAL COMPONENT

Product design in the early stages requires a more quantitative process to ensure that simulation study's outcome will meet expectations. The purpose of this study was determine whether manufacturing software package could effectively evaluate and validate conceptualised blank tooling manufacture sizeable complex- shaped aluminium alloy aircraft panel using die sheet hydroforming. Blank tool concepts were conceptualised, evaluated, validated digitally forming conceptualisation cycle. Without need trial several physically, significant saving achieved resource-efficient development process. Even without modelling hyperelastic rubber elements, successful hydroformed result conducted. However, showed rubber-to-metal friction coefficient must be incorporated appropriately. further lack standard metrology methods commercial packages accurately. Simulation is new area interest development. This research contributes improving metal and, specifically, hydroforming simulation. benefit aerospace automotive industry promote adoption digital processes.